Welding apparatus



Feb. 19, 1946. H, MORRIS WELDING APPARATUS Filed Aug. 29, 1941 9 Sheets-Sheet 1 39a 3 INVENTOR. HOWARD I. Mann/s maxim ATTORNEY.

Feb. 19, 1946. H. l. MoRRls WELDING APPARATUS Filed Aug. 29, 1941 9 Sheets-Sheet 2 mm mmw INVENTOR. H0 WARD I Mann/5 ATT RNEY Feb. 19, 1946. H. l. MORRIS 2,395,059

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H. l. MORRIS WELDING APPARATUS Filed Aug. 29, 1941 Feb. 19, 1946.

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9 Sheets -Sheet e III/II INVENTOR flOWARD I. Mann/s Filed Aug. 29, 1941 fi /wm ATTORNEY Feb. 19, 1946. .1. MORRIS WELDING APPARATUS Filed Aug. 29, 1941 9 Sheets-Sheet '7 ildllllllllnl/llzl a F7615 INVENTOR. Ho wnno f. Mann/s AmmvEx Feb, 19, 1946. H. l. MORRIS WELDING APPARATUS Filed Aug; 29, 1941 9 Sheets-Sheet 8 1N VENTOR.

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Feb. 19, 1946. H. l. MORRIS 7 2,395,059

WELDING APPARATUS Filed Aug. 29, 1941 9 Sheets-Sheet 9 FIG; 22 1 76.33

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ATTORNEY Patented Feb. 19, i946 WELDING APPARATUS Howard K. Morris, Lakewood, hio, -assignor of one-third to Carl M. Yoder and one-third to Harvey 0. Yoder, both of Lakewood, Qhio Application August 29, 1941, Serial No. 408,883 12 Claims. (Cl. ne -s)- This invention relates to electrical welding apparatus, more particularly to apparatus of the resistance type utilizing direct current for welding and employing rotatable electrodes. The apparatus may be used for welding various kinds of work, but for illustrative purposes it is shown as applied to the welding of the seams of pipes or tubular members.

One object of the invention is to provide a direct current welder wherein the direct current supply means rotates withthe electrodes to there" by simplify the apparatus, increase the efficiency and reduce the cost of installation and operation.

Another object of the invention is to construct an improved direct current welder comprising a unitary, rotatable apparatus arranged to transform the supplied alternating current to the proper voltage for welding, rectify the current into direct current and supply the latter to the welding electrodes.

Another object of the invention is to provide an improved direct current welder wherein the supplied alternating current is transformed to the desired welding voltage and rectified into direct current and the direct current supplied to the welding electrodes through conductois to tions are effected byhighly simplified apparatus and the expense of a separate apparatus for supplying direct current at low voltage is eliminated.

Another object of the invention is to provide an improved welding apparatus comprising a transformer for-stepping down the A. C. current to a suitable welding voltage, a rectifier and the welding electrodes, mounted to rotate as a unit, withthe electrodes in engagement with the work and wherein the rectifier is constructed to permit ready cooling thereof.

Other objects of the invention will be apparent to those skilled in the art to which my invention relates from the following description taken in connection with the accompanying drawings, wherein Figs. 1 and 1A together show a direct current welding apparatus embodying my invention and illustrated as employing a three phase transformer; parts in Fig. 1 being broken away and Fig. 1A being partly in section on the line lA--l A of Fig. 2.

Figs. 2, 3 and 4 are sections on the lines 2-2, 3-3 and 4-4, respectively of Fig. 1A.

Figs. 3A and 3B are fragmentary views, partly in section on the lines 3A--3A and 3B-3B, re-

spectively, of Fig. 3, enlarged.

Figs. 5 and 6 are detail views.

Figs. 7, 8, 9, 10 and 11 are sections on the lines '|-l, 8-8, 9--9, |0I0 and II, respectively of Fig. 3.

Fig. 12 is a fragmentary view of parts shown in Fig. l, somewhat enlarged and partly in section on the line i2--i2 of Fig. 13.

Fig. 13 is a section on the line l3l3 of Figs. 1A and 12.

Fig. 14 is a diagrammatic view of the circuits.

Fig. 15 is a diagram of the rectified current.

Fig. 16 is a fragmentary section on the line i$l6 of Fig. 17 showing a modified form of rectifier.

Fig. 17 is a fragmentary section on the line li-l'l of Fig. 16.

Fig. 18 is a view partly in section and partly in elevation of a modified formof direct current welding apparatus employing a single phase transformer.

Figs. 19 and 20 are sections on the lines 19-49 and 20-20, respectively of Fig. 18.

Fig. 21 is a diagram showing the rectified current in the form of construction shown in Fig. 18.

Figs. 22 and 23 are fragmentary views, partly in section on the lines 2222 and 2323, respectively, of Fig. 20.

In the drawings, l indicates as an entirety a base member supporting in spaced relation a plurality of hollow uprights 2 (preferably four in number but only one being shown) each forming a bearing for a spindle or shaft 3. Each spindle.

3 is provided with a collar 3a which engages a suitable thrust bearing 3b mounted in the upper end ofthe adjacent upright 2. That portion of each spindle 3 above its collar 3a is provided with screw. threads, as shown at 3', and fits into and,

the spindles 3 serves to raise or lower the frame 5, the efiect of which is to (a) insure effective frictional engagement between the electrodes 5, 6a, and the pipe A, whereby the movement of the pipe A. rotates the electrodes and parts connected thereto, or (bi raise the electrodes clear of the pipe A, as when it is desired to re-finish the peripherles of the electrodes.

The base member 1 supports a gear box I, in which are mounted spaced shafts lo, the latter extending upwardly and provided on their upper ends above the box l with pressure rolls which engage the sides of the pipe A. The shafts To may be driven in opposite'directions by the gearing within the box '1; suitable rolls (not shown) serve to feed the pipe A endwise. The rolls ii are removably mounted on the shafts id, so that rolls having varying curvilinear shapes in cross section may be mounted on the shafts. The pipe A may be supplied in lengths or sections or supplied continuously from a suitable forming or shaping mechanism (not shown).

The frame 5 forms a support for a rotatable mounting 5' on which is supported the welding mechanism consisting (a) of three single phase transformers (each connected on a different phase interconnected to constitute a three phase transformer, indicated as an entirety at 8, (b) the electrodes G, Ba, and (c) a rectifier, indicated as an entirety at l 0, the input side of which is electrically connected to the ends of the secondary winding of each of the transformer units 90;, 92?, So, as later set forth, and the out-put side of which is electrically connected to the electrodes 6, So (as later set forth). Each transformer unit 9a, Eb, 50, consists of a suitable laminated core a primary winding 9a and a secondary winding 90." having terminals l1, Ila (see Figs. 1, 3A, 3B and 4). The transformer units are wound to reduce the voltage supplied by the mains (later referred) to a suitable welding voltage, which may vary from approximately three to six volts.

Ea, iicz, indicate suitable hangers depending from the opposite ends of the frame 5 and each provided at its lower end with suitable antlfriction bearings it (see Figs. 1 and 1A), which support one end portion of the mounting 5. The hanger to adjacent to the electrodes 5, 6a, is removably secured to the frame 5 in any desired manner. In the arrangement shown, the frame 5 is provided with a pair of outwardly extending pins (only one being shown) having threaded outer end portions and the hanger 5a is formed with through openings 5.2: to receive the pins and nuts 5x" tightened on the pins 55: against the han er 5o serve to removably secure the latter in position.

The mounting "3' comprises three sections 92, We, @222, the tran former units 9a, 9b, 9c, being positioned within and in fixed relation to the section 62 and the sections formed of suitable conducting ZZl as copper, and serving as conductor a output terminals of the rectifier l3 8, do, respectively, the rectifier it being inter posed between the inner ends of the conductor devices its, We, and the terminals ll, Ila, oi the secondary windings 8a" of the transformer units to, to. The section i2 preferably consists of a cage-like device having a plurality of arms i3 (preferably three arms) integrally connected together at their ends adjacent the electrodes 6, 6:1, by bars it and integrally connected at their opposite ends to a hub H3. The hub i5 ff" L101:

1 to the electrodes e is rigidly connected to the inner end of a tubular shaft l5a, the axis of which is in line with an imaginary center about which the arms 13 are positioned. The shaft 5a is mounted in the adjacent bearing H as shown in Fig. l. The sections I241, 12b, consist of inner and outer concentrically related devices electrically and rigidly connected at their outer ends to the electrodes 6. 6a, respectively (the inner device lZa having an extension I21: which is mounted in the adiacent bearing l|--see Fig. 1A) and provided at their inner ends with annular members IZa, lZb, respectively, electrically connected to the out-put side of the rectifier H), as later set forth.

The parts of the mounting 5' and the rectifier [0 are rigidly secured together by bolts l6 engaging pads Ha, integrally connected to the arms l3 and bars I4, and the marginal portion of the annular member I 222', the bolts l6 extending through certain parts of the rectifier in as later set forth. As shown in Figs. 7 and 3A, the bolts [6 are suitably insulated from the pads Ha, the adjoining terminals l1, Ha, of the secondary windings 5a of the transformer units, the annular member lZb' and other parts later referred to by the insulation material l8 and a sleeve it! formed of insulation. material.

The terminals H, Ila, of each of the secondary windings 9a are insulated from the mounting section l2 by suitableinsulation material l9 (see Figs. 1A, 7 and 3A); also, the mounting sections 12a, 121), are insulated from each other by suitable insulation materlal 20, H; also, the extension 12:1: is insulated from the adjacent hanger So by insulation material 22 and the electrodes 6, 6a, are insulated from each other by suitable insulation 23.

The conductor device I2!) is reduced at its outer end to form a seat for the electrode 6, which is secured to the conductor device by countersunk screws 24; also, the conductor device l2a is reduced at a point beyond the conductor l2b to form the extension 123:, the resulting shoulder forming a seat for electrode 6a and the opening in the latter being rabbeted to fit over said shoulder. The electrode 6a is held in position in its seat by a ring nut 25 threaded on the extension Hat.

The electrical connections to the primary windings 9a comprise the following: 26, 26a, 26b, indicate leads leading from the terminals 21, 21a, 2722, respectively, to the primary windings, the terminals being integrally connected to conductors 28, (only one being shown-see Fig. 12) and the latter in turn being connected at their outer ends to current collecting rings 29, 29a, 2%, respectively. Each terminal 21, 21a, 2711, the conductor 28 and ring connected thereto are insulated from the remaining corresponding parts and she it 55a by suitable insulation material 30 (see Fig. 12). 3!, Sid. 3th, indicate rods formed of conducting material, one for each supply main 32 (only two supply mains being shown in Fig. 12), mounted in and extending through the adjacent hanger So, each rod having a collar 33 engaging the inner face of the hanger 5a to which it is clamped by a nut 33a on the outer end of the rod engaging the outer face of the hanger, a separate nut 33a serving to secure the adjacent main 32 to the nut 33a. The collar 33 and nut 33a on each rod 3!, Illa, 3122, are insulated from the hanger 5a by washers 331) formed of suitable insulation material and each rod is insulated from the hanger by a sleeve 330 formed of suitable insulation material. The inner end of each rod 3!, 31a,

lib, extends through an opening formed in an arm 34 integrally connected to and extending radially of an annulus 35 which is formed of conducting material and surrounds one of the collecting rings 28, 29a, 29b. Each arm 34 is split, as shown at 34', so that by means of a screw 8412 the split portions may be drawn toward each other to rigidly secure-the arm to the adjacent rod and hold the adjacent annulus 35 in position. Each annulus 35 is formed with a radial slot 38- preferably three slots, in which a suitable brush 3! is slidably mounted to engage the adjacent collecting ring 28, 29a or 29b. 38 indicates a pair of annular disks formed of insulation material surrounding the, shaft lia, one being disposed between the collecting rings 29, 29a, and the other being disposed between the collecting rings 23a, 29b. The disks 38 are formed with sets of alined openings "a, one set for each rod 3i, Ila, Slb, through which the rods extend to support the disks in position. The disks 38 support between them blocks 39, each related to one of the adjacent brushes 31 and formed with a threaded opening for an adjusting screw 40 which engages the adjacent brush to hold it in engagement with the adjacent collecting ring 29a. The adjusting screws 40 for holding the brushes 3? in engagement with the rings 29 and 291) are mountedin blocks 39a which are secured to the opposite outer faces of the disks 38.

The rectifier consists of a form of construction wherein the alternate flow of current in one direction from the terminals of the secondary winding of the single phase transformer (see Figs. 18, 19, and 20) or each unit of a three-phase transformer (see Figs. 1A to 11) always flows to one electrode 6 or Go and the flow of current in the opposite direction always flows from the other electrode to said terminals alternately; accordingly the alternating current is rectified into direct or uni-directional current, as shown in Figs. 14, 15 and 21.

In the form of construction shown in Figs. 1A to 11, inclusive, andFigs. 3A and 3B, employing a three-phase transformer, the rectifier lll is electrically connected to the terminals of the secondary winding of each transformer unit and the conductor devices l2a-l2a' and llb-llb' in the same manner so that reference to these connections (for example for the unit 9b) will sufllce for the remaining units, similar parts in the connections for the remaining units being identified by the same reference characters. In this anrangement I provide for each transformer unit (a) a pair of conductors electrically connected with the terminals of the secondary winding of the transformer unit and a conductor intermediate thereto electrically connected with one of said conductor devices l2a, lib, and rectifying elements between each said conductor, which is connected to the said terminals, and the adjacent intermediate conductor which is connected to one of the conductor devices l2a, lib, each element carrying a rectifying medium (indicated by the heavy line X in Figs. 7 to 11, inclusive). which permits flow of the current into or through the element in one direction only; (b) a pair of conductors, electrically connected to the secondary winding terminals of the transformer unit, a conductor intermediate said pair of conductors, electrically connected to the other. conductor device and separate rectifying elements between said intermediate conductor and said pair of conductors. Accordingly, the alternate flow of current in one direction from the secondary winding terminals flows to one conductor device lZa or lib and the electrode connected thereto and the current in the opposite direction from the other electrode and the conductor device connected thereto flows through the other intermediate conductor to the adjacent pair of conductors alternately and from the latter to the terminals of the secondary winding of transformer unit.

It will thus be understood that when current flow is from the terminal l'l (arrows m) through the conductor 4|, the current flow in the opposite direction is through conductor '45, rectifying elements 44' (arrows :r') and conductor 44a to terminal lla; upon reversal of the current, current flow is from the terminal lla, through conductor 4la (arrows :c") and the current flow in the opposite direction is through conductor 45, rectifying elements 48 (arrows :c) and conductor 44 to the terminal II.

Referring to Figs. 3A and 3B, which are en larged views on the lines lA-BA and 33-33, respectively, of Fig. 3, 4i, 41a (Fig 3A), indicate a pair of conductors in electrical connection with the secondary winding terminals l1, Ila, and 42 indicates a conductor intermediate the conductors 4|, 41a, in electrical connection with the conductor device lib. 43 indicates the rectifying elements between the conductors M, Ma, and the conductor 42. 44, 44a (Fig. 38), indicate a pair of conductors in electrical connection with the secondary winding terminals ll, flu, and 45 indicates a conductor intermediate the conductors 44, 44a, in electrical connection with the conductor device Ila. 46 indicates the rectifying elements between the intermediate conductor 45 and the conductor 44, and 48' indicates the rectifying elements between the intermediate conductor 45 and the conductor 44a.

In the arrangement above set forth, when the current-is flowing from one terminal (for example, terminal of the secondary winding to"), it flows through the conductor 4! (see arrows x-Fig. 3A), the rectifying elements 43 and the intermediate conductor 42 to the conductor device l2b'-l2b, which is connected to the electrode 6 and through the work to the electrode 6a;

and simultaneously the current from the electrode 8a is flowing through the conductor device Ila-42a to the intermediate conductor 45 (see arrows :c'Fig. 3B), the rectifying elements 46' between itand the conductor 44a to the latter conductor, and to the other secondary winding terminal "a. Upon the reversal of current in the secondary winding 9a" of the unit 9b, the current flows from the terminal l'la through conductor 4la-(see dotted arrows a:"Fig. 3A), rectifying elements 43, intermediate conductor 42 and conductor device l2b'--l2b to the electrode 0 and through the work to the electrode to; and simultaneously the current from the electrode 6a is flowing through the conductor device l2ai 2a to the intermediate conductor 45 (see dotted arrows :r"'-Fig. 3B), rectifying elements 46 and conductor 44 to the terminal H.

The current flow as above described is effected by providing betweencach intermediate conductor (42 and 46) and the conductors related there...

to (which are electrically connected to the terminals N, Na, respectively), rectifying elements each constructed to rectify the alternating current, so that such current always flows therethrough in one direction. To secure this result, each of the rectifying elements consists of a plate 41 formed of copper. having on corresponding portions of its opposite surfaces layers of copper oxide and on each surface of the copper oxide "'ZSWS from. the terminates ll, lid

22; whereas the intermediate conductor el ctrically contacts the copper layers ll and the adjacent conductors 44, a electrically contact the portions 41a of the copper plates at, so the opposite polarity of the current flows from he conductor 45 to the rectifying elements 53 alternately.

It will thus be seen that the rectifying elements are provided with a current rectifying medium, whichis interposed in the path of current flow between the secondary winding terminals l'l, Ho, and the electrodes ta, and by providing a rectifying element between each secondary winding terminal and on of the electrodes and a rectitying element between the other electrode and each secondary winding terminal, the supplied is rectified supply direct current flow in one direction to one electrode and through the work to the ot er electrode and direct current flow i the opposite direction from the latter electrode.

As shown, (a) I provide a plurality of rectifying elements it between each intermediate conductorfiii and the adjacent conductors 4!, die, respectively, one of these elements being shown Fig. 6, is being noted that each set of rectiing elements 33 is common to the adjacent conuctors ii, lia; and (b) I provide a set of rec ifyln elements between each intermediate con ucto c5 and each of the adjacent conductors it, ide. tl 'hile these sets of rectifying elements are connected to the terminals i'l, lie, of the adjacent transformer unit (for example unit 22b), each set is electrically connected to one set of rectifying elements of the units So, So, that is, each element of each set is electrically connected with one element or one set of elements for one of the other units, as will be understood from Figs. 3, 3B and 5.

Each of the conductors it, Ma, consists of a plurality of blocks lid, each formed of copper, spaced to receive between them the adjacent end portions of the rectifying elements #53, so that portions of the blcci: overlap and electrically contact with the copper layers d9 thereon. As shown in Figs. 3, 3A and '7, the blocks 50 are formed with (a) alined openings 56a to receive a bolt which is insulated from the adjacent pad Eta and conductor device i2bl 222 by sleeves formed of insulation material, and alincd openings in alinement with aiined openings formed in adjacent rectifying elements 1.; to receive the bolts the bolts i and serving to clap the blocks 56 and rectifying elements it togct cl and to the adjacent secondary winding te 'nal (ll or lid) and conductor device i2b" As shown, the bolts it are insulated from the adjacent pad Ha, terminal, blocks 5Q, rectii ing elements 43 and conductor device i2b52l2, as already set forth; also, the block adjacent to the conductor device lZb-2b is insulated from the latter by a sheet of insulation material As shown in Fig. 3A,

reg

the free ends of the rectifying elements 53 are spaced from those blocks which are in opposed relation to such ends to prevent contact of said blocks with the copper plates 41.

- As will he understood from Figs. 3 and 7, the blocks to forming each conductor 4!, Ha, are common to one secondary winding terminal of one transformer unit and the opposite terminal of the secondary winding of the adjacent trans,- former unit.

The intermediate conductor 42 consists of a plurality of blocks spaced to receive between them the rectifying elements 43, but as the layers of copper oxide 48 and copper layers 49 terminate at points remote from the opposite sides of the blocks 55, the latter electrically contact the copper plates 4'! accordingly, the current from either terminal l? or Ha, flows through the adjacent conductor ll or Me, copper layers 49 and layers of copper oxide 48 to the copper plate 41 and to the blocks 55, which are in electrical contact with the conductor device l2b'-l2b. The block 55 adjacent to the terminals l1, Ila, is insulated therefrom by a sheet of'insulation material 56. To compensate for the thickness of the sheet 56, a sheet of copper 58a is interposed between each block 50 adjacent to one of the terminals 11, Ha, and the latter. Likewise, to compensate for the thickness of the insulation sheet 54, a sheet of copper 57 is interposed between the block 55 ad.- jacent to the conductor device l2b--l2 and the latter. 'The blocks 55 and copper plates 41 are formed with sets of alined openings, to receive bolts 58 which rigidly clamp the blocks 55 and plates ti together and to the terminals 11, Ha, and conductor device i2b'--l2b, the bolts being insulated from these parts by sleeves 59 and washers 56, eachv formed of suitable insulation material.

The intermediate conductor 15 consists of a. plurality of blocks 8! formed of copper and spaced to receive between them the adjacent ends of the rectifying elements 46, 46. The blocks 8! are formed with sets of alined openings 62 alined with openings 62c formed in the rectifying elements E5, 45', to receive screws 63 to clamp these parts together and to the conductor device liar-42a and terminals ll, Ila, the heads of the bolts being countersunk in the conductor device life and their opposite ends being threaded into the terminals 5?, Ha, respectively (see Fig, 3B). The bolts 63 are insulated from the blocks BI and elements t l, 46, by sleeves 64 formed 01' insulation material and insulation 55. Each of the conductors it, Ma, consists of a plurality of blocks 56 formed of copper and spaced to receive between them the plates 4! forming parts of the adjacent rectifying elements. The blocks 86 and plates i? are formed with alined openings 67 to receive a screw 58 which clampsthese parts together and to the conductor device l2a'--l2a and adjacent secondary winding terminal, the head of the screw being countersunk in the conductor device its. its opposite end being threaded into the adjacent terminal. The screw 68 is insulated from the conductor device lZa' by sections of insulation material 68. The block adjacent to the conductor device lZa is insulated therefrom by a sheet of insulation material 10 the thickness of the sheet 10 is compensated ior by spaced sheets of copper Tl between the block 5i adjacent to the conductor device Ila and the latter. The block.8l adjacent to the terminals 21, Ila, is insulated therefrom by a sheet of suitable insulation material 72 and the to the welding electrodes are bridged by a pin-- rality of rectifying paths, each consisting of two rectifier units connected in series (such as units 48 and 48), and each point of the delta connection is connected to the midpoint of one of the rectifying paths. While sixrEctifying paths are shown in Fig. 14, it is obvious that only three paths are essential for full wave rectification from the delta connection of the secondary winding.

14 indicates as an entirety means for positively rotating the mounting such operation permitting the application of a suitable tool to the peripheries of the electrodes 8, 6a, to refinish them. The rotating means 14 comprise a motor 15 supported on the frame 5 and a power transmitting 'mechanism between the motor shaft and mounting 8'.

The power transmitting mechanism consists of the following: 16 indicates a movable clutch element splined on the extended end of the motor shaft and operated by a yoke 18a into and out of engagement with a clutch element 11 loose on the motor shaft, a sprocket l8 fixed to the clutch element 11 and an endless chain 18 engaging the sprocket l8 and a sprocket 88 fixed to the hub l5.

Provision is made for cooling the electrodes 8, So, by water or other liquid and cooling the rectifier III by air, the construction of the latter, as already set forth, permitting the circulation of air into and through all parts thereof and the escape of the air from the rectifier. As shown in Figs. 1A, 3 and if, the terminals ll, Ila, of the transformer units 8a, 8b, 8c, and sets of recti-' fying elements 48, 48', are cut away or shaped at their inner ends to form an enlarged opening or area 8| between the transformer units and the annular member l2a' of the conductor device l2a, the annular member Ila serving to close the outer end of this opening and thus force all of the air supplied into the inner end thereof into and through the parts constituting the rectifier Ill. The air is supplied to the opening 8| by a pipe 82, the inner end of which terminates at the inner end of the opening 8| (preferably within the inner ends of the terminals Ilasee Fig. 1A), said inner end of the pipe 82 being supported in an opening formed in a bar 83 of insulation material secured to the terminals |l, Ila, by screws 83a (see Fig. 2). The outer end of the pipe 82 is connected to the inner end of the hollow shaft l5a, the outer end of which is connected to the discharge nozzle or outlet 84 of a suitable blower 85, the rotor of which is driven by a motor 85a see Fig. l). The discharge nozzle 84 of the blower extends into and loosely fits the hollow shaft I 5a. The blower 85 is rigidly connected to the frame 5 by suitable brackets (only one thereof being shown at 85b) whic maintain a collar 88 adjacent the end of th discharge nozzle 84 against an annular wall 81, preferably consisting of a ring nut threaded on the adjacent end of the shaft I511. The lower 85 therethrough and accommodate inner and outer water circulating pipes 88, 88. The inner end of the pipe 88 is threaded into the outer end ofan opening 80 formed in the conductor device lid.

The pipe 88 extends from the device |2a outwardly through the discharge nozzle or outlet 84 of the blower 85 and the remote end wall of the outlet, its outer end being rotatabiy mounted in a fitting 8| and connected through the latter to a discharge pipe 82 leading to a sump or sewer (not shown). The pipe 88 is rotatably mounted at its outer end in the fitting 8| and connected therethrough with a water supply pipe 83 leading from a source of supply under suitable Pressure. The pipe 88 extends through the pipe 88 and opening 88, its inner end fitting into and supported by the closed inner end walls of the opening 88, the inner end of the latter being preferably reduced to form a seat for the pipe. Inwardhr of the seat for the pipe 88, the opening is enlarged and the side walls of the pipe opposite said enlargement are formed with ports through which the water supplied into and through the pipe 88 is discharged for return fiow through the opening 88, pipe 88, fitting Si and discharge pipe 82.

As shown in Fig. l, the outer end of the pipe 88 extends through and rotates in a bushing 84, formed of suitable insulation material, and

mounted in the outer end wall for the outlet 84,

whereby the pipes 88, 88, are insulated frommelting point of the copper for a sufficient length of time to produce coatings of copper oxide 48 on their opposite surfaces. The plates are then removed and when cool pure copper is sprayed on the surfaces of the copper oxide to apply thereto the copper layers 48. Thereafter predetermined portions of the copper oxide layers 48 and copper layers 48 are removed, as by a grinding operation, as shown in Figs. 5 and 6, to expose fled form of construction wherein a single phase supplies air under pressure through the haft lia transformer is employed, (a) the primary winding of which is connected to leads 85, receiv ing A. C. from mains 32a through the electrical connections, indicated as an entirety at 88, these connections being preferably constructed similarly to corresponding parts shown in Figs. 1A, 12 and 13; and (b) the secondary winding of which is connected to terminals I5x, iix'. Referring to these views, 51: indicates a mounting rotatably supported in bearings (one bearing being shown at Hz) constructed similarly to that shown in Fig. 1A, except that the section in is provided with four arms |8:z: (see Fig. 20). The welding mechanism comprises the single phase transformer'iix, the core 81: of which is rigidly secured to the arms l3a: by bolts i8rc', electrodes terminal.

vely, and having integral extension members ides", My, respectively (electrically insulated the mounting section as shown at I232), and a rectifier 1011:. These parts just referred to, except the rectifier Him, are substantially similar in construction to corresponding parts already described in connection with Figs. 1A to 13, inclusive.

The rectifier I01: consists of a pair of rectifying elements 91, 91a, interposed between and electrically connected to the extension members Mr, My, respectively, and the secondary winding terminal I:r and a pair of rectifying elements 98, 98a, interposed between and electrically connected to the extension members I 4:2, I-iy', respectively, and the secondary winding terminal I512.

Each rectifying element 91, 91a, 08, 88a, consists of a plate of copper 89, one surface of which is provided with a coat or layer of copper oxide 99a. As shown in Fig. 22, the layer of copper oxide 99a on the rectifying element 9.1 is disposed adjacent to the terminal 152', whereas the copper oxide on the rectifying element 91a is disposed adjacent to the extension My; and as shown in Fig. 23, the copper oxide 99a on the rectifying element 98 is disposed adjacent to the terminal I 5:1: whereas the copper oxide on the rectifying element 98a is disposed adjacent to the extension member My. In this arrangement of the rectifying elements, when the polarity of the current to the terminal I532 is positive, the current flow is from terminal I512 through the rectifying element 91, extension member I 4x, conductor device I la: to the electrode 6:2 (see arrows Z) and through the work to the electrode 0x, and from the latter electrode through the conductor device My, extension. member My, rectifying element 98a to the terminal (see arrows Z); upon reversal of current in the secondary winding, current flow from the terminal I5x is through the rectifying element 98, extension member I4x', conductor device I laz, electrode 6a: (see dotted arrows Z) and through the work to the electrode 61: and from the latter electrode through the conductor device My, extension My, the rectifying element 01a to the terminal I5x' (see dotted arrows Z). Accordingly, t will be seen that direct or unidirectional current will be supplied alternately from the rectifying elements, 91, 98, in contact with the terminals I593, 152:, respectively, to the electrode and through the work to the electrode 63: and return from the latter to the rectifying elements 98a, 97a, and alternately through the latter to the terminals I5r, respectively.

By preference, I provide between the opposite surfaces of each rectifying element 91, 91a, 98, are and the adjacent secondary winding terminal and extension member sheets of relatively soft conducting material, such as lead I00, all of these parts being secured together in face to face relation by a plurality of screws Ifii, which extend therethrough, the head of each screw being counter-sunk in the adjacent extension member and its free end being threaded into the adjacent Each screw iDI is suitabl insulated from the extension member, rectifying element and lead sheets by insulation material 502, as shown in Figs. 22 and 23. The soft characteristic of the lead sheets enables them to engage uneven. portions of the surfaces with which they engage and accommodate themselves to t rough surfaces of the copper oxide, to insure a uniform x, 511: (electrically insulated from each other),

flow of the current throughout all portions of the respective rectifying elements.

It will be noted that the screws IOI, secure together the terminals I 5:c, I5, to the extension members Mr, My; also that bolts I03 secure the extension members to the arms 13:, so that all parts of the welding mechanism rotate as a unit.

It will be understood that the number or rectifying elements between each extension member Hr, Hg, and the adjacent terminal may be increased dependent upon the amount of current that is to be used in carrying out an particular welding operation.

In the use of a single phase transformer and rectifier direct current as shown diagrammatically in Fig. 21 is produced, whereas in the employment of three single phase transformers interconnected and each on one phase, a much smoother direct current is produced, as diagrammatically shown in Fig. 15.

Figs. 16 and 17 illustrate a rectifier I0:c of the electrolytic type, disposed between and electrically connected to the terminals I04 of each transformer unit and the extension members I05, I05a, oi. the conductor devices I05, I05a', respectively. As shown, I provide for each transformer unit I05 (a) a pair of containers I 01, I01a, containing the electrolyte B, the container I01 having poles I01, |01a', submerged therein and the container I01a having poles I011, I01x, submerged in the electrolyte B; the poles I01, I01r, are connected to the adjacent secondary winding terminal I04 by studs I08 formed of copper, whereas the poles I01a, I01r, are electrically connected in a similar manner to the extension members I05, I05a, respectively; and (b) a pair of containers I09, I09a, containing the electrolyte B having submerged therein poles electricall connected to the adjacent parts, similarly to that shown in Fig. 16, except that the poles, which correspond to the poles I01, I01m', shown in Fig. 16, are electrically connected to the other secondary winding terminal. Assuming that the current flows in the direction of the arrow 12, such flow will be from the terminal I00 through the pole I01, electrolyte B in container I01, pole I01c, extension member I05, conductor devices I05 to the adjacent electrode and through the work to the other electrode and from the latter electrode through conductor device I05a', extension member I 05a, poles connected thereto submerged in container I09a, the electrolyte B therein and the poles connected to the other secondary winding terminal. Upon the reversal of the current, the flow will be from the other secondary winding terminal through the pole I01 in container I09 and the electrolyte therein and return through pole I010: in container I01a, the electrolyte in container I01a and the pole I01;r (see arrow b) to the adjacent secondary winding terminal I04. The walls of each container is formed of suitable insulation material. Where the electrolyte B consists of a solution of borax, the pole I01, the corresponding pole in container I09 and the poles I01x are preferabl formed of aluminum and the remaining poles are formed of lead. Where the electrolyte B consists of sulphuric acid the poles I 01, the corresponding pole in container I09, and poles I011: are preferably formed of tantalum and the remaining poles are formed of lead. It will be understood that other electrolytic solutions may be used and that the poles may be formed of such materials as will be found most desirable or effective according to the kind of electrolyte used.

From the foregoing description it will be noted that I have provided a rotary welding mechanism, which includes a rectifier, so that the transformer, rectifier and electrodes rotate as a unitary structure, and by way of example, certain forms of rectifier are of the junction type and a modified form is of the electrolytic type. It will also be noted that this arrangement results in a materially simplified, economical construction and insures highly efficient results.

To those skilled in the art to which my invention relates, many changes in construction and wdely differing embodiments and applications the invention will be apparent without departing from the spirit and scope thereof. My disclosures and the illustration herein are purely illustrative and are not intended to be in any sense limiting,

What I claim is:

1. In apparatus of the class described, the combination with a support, of a sectional frame rotatably mounted on said support, current rectifying means, a transformer fixedly related to one section of said frame and rotatable therewith and having the terminals of its secondary winding electrically connected to said rectifying means, other sections of said frame consisting of conductor devices electrically insulated from each other and the first mentioned frame section and electrically connected to said rectifying means, said current rectifying means being mounted between and rigidly secured to said frame section to which said transformer is fixed andsaid other frame sections, and electrodes fixedly related and electrically connected to said conductor devices. it

2. In apparatus of the class described, the combination with a support provided with bearings, a welding mechanism rotatably mounted on said bearings and comprising a frame the outer end of which engages one of said bearings, conductor devices having extension members rigidly connected to the opposite end of said frame and electrically insulated therefrom, one of said conductor devices engaging the other bearing, electrodes fixed to and electrically connected to said conductor devices, respectively, and electrically insulated from each other, a transformer fixedly related to said frame and rectifyin elements disposed between and electrically connected to the terminals of the secondary winding of said transformer and said extension members, and means for supplying alternating current to the primary winding of said transformer,

3. In welding apparatus, the combination with a support having spaced bearings, of a unitary assembly mounted on said bearings and comprising a pair of circular welding electrodes mounted for rotation about the-axis-of said bearings, a supply transformer also mounted to rotate with said electrodes about the same axis, a rectifier assembly mounted for rotation with said transformer and electrodes, said rectifier assembly comprising a plurality of uni-directional conductive elements symmetrically disposed about said axis and in spaced relation to each other to permil: air to fiow between said elements radially from said axis, connections for supplying alternating current to said rectifier assembly from said transformer, and connections for supplying direct current from said rectifier assembly to said electrodes.

4. Welding apparatus according to claim 3 wherein said supply transformer comprises a multi-phase transformer formed of a plurality of single-phase transformers symmetrically diseach point of said delta connection to the respective midpoints of said bridging paths.

6. Welding apparatus according to claim 3 wherein said rectifier is of the dry contact type and comprises a plurality of .spaced parallel plates arranged so that the spaces between said plates form ventilating channels arranged radially with respect to the axis of rotation of said rectifier.

'7. Welding apparatus according to claim 3 wherein said rectifier comprises a plurality 0! rectifier-units of the dry contact type symmetrically arranged around the axis of rotation of said electrodes and spaced from said axis to provide an open space in the center of said rectifier, said rectifier units being formed of a plurality of spaced plates arranged so that the spaces between said plates form ventilating passages leading from said central open space to the outer periphery of said rectifier, an air supply tube arranged concentrically with the axis of rotation of said electrodes and having one end thereof communicating with said central opening in said rectifier, and means for supplying air under pressure to the other end of said tube.

8. In welding apparatus, the combination of a pair of circular welding electrodes mounted in bearings for rotation about a common axis, a rectifier assembly mounted for rotation with said electrodes and comprising a plurality of rectifier units symmetrically arranged around the axis of rotation of said electrodes and being spaced from said axis to provide an open space at the center of said rectifier assembly, an air supply tube arranged concentrically with the axis of rotation of said electrodes and having one end thereof communicating with said open space in said rectifier assembly and the outer end thereof extending through one supporting bearing for said electrodes, and means for supplying air under pressure to the outer end of said tube.

9. In combination, a frame journaled in a bear ing for rotation about a given axis, a rectifier assembly mounted on said frame for rotation about said axis and comprising a plurality of rectifier units symmetrically arranged around said axis and spaced therefrom to provide an open space in the center of said rectifier assembly, said rectifier assembly having ventilating passages ex tending from said open space to the outer periphery thereof, and an air supply tube passing through said bearing concentrically with said axis of rotation and having the inner end thereof communicating with said central opening.

10. In welding apparatus, the combination with a support having spaced bearings, of a unitary assembly mounted on said bearings and comprising a pair of circular welding electrodes mounted for rotation about the axis of said bearings, a supply transformer also mounted to rotate with said electrodes about the same axis, a rectifier assembly mounted for rotation with said transformer and electrodes, said rectifier assembly comprising a plurality of uni-directional conductive elements symmetrically disposed about said axis and in spaced relation to each other, means for causing air to flow radially out from said axis iii 51,395,059

in contact with said elements to cool the same, connections for supplying alternating current to said'rectifier assembly from said transformer, and connections for supplying direct current. from said rectifier assembly to said electrodes.

11. An apparatus as claimed in claim 1 wherein the current rectifying means is of the electrolytic type.

12. An apparatus as claimed in claim 1 wherein said current rectifying means consist of cham Certificate of Correction Patent No. 2,395, 059.

February 19, 1946.

HOWARD I. MORRIS t is hereby certified that errors appear in the printed specification of the above numbered patent requiring correction as follows: Page 5, second column, line 37, for

day read dry; page 6, first column, line 52, for 100:

first occurrence, read 152:;

and that the said Letters Patent should be read with these corrections therein that the same may conform to the record of the case in the Patent Oflice.

Signed and sealed this 21st day of May, A. D. 1946 LESLIE FRAZER,

First Assistant Commissioner of Patents. 

